Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||||
| 06213 | 06223 | 10019380 | White smoke, lacks power, exhaust odor, surges, runs rough, or no start - 6.0l. *tt | 03/13/2006 | |
| 041601 | 11/14/2005 | 05228 | 10018745 | Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running. *tt | 01/12/2006 |
| 18845 | 09/01/2005 | 10018073 | Flutter noise on deceleration. *tt | 12/14/2005 | |
| 051713 | 10/07/2005 | 05249 | 10018062 | Coolant degas bottle overflow. *tt | 12/14/2005 |
| 18525 | 04/01/2005 | 10017875 | Buck/jerk, lacks power, black smoke, rolling idle, surge, mil on, and diagnostic trouble codes p2263, p0299, or p0401. *tt | 12/06/2005 | |
| 18734 | 07/01/2005 | 10017864 | Diagnostic trouble code p0488 set after reflash. *tt | 12/05/2005 | |
| 05215 | 10/31/2005 | 10017806 | Buck/jerk or surge - 6.0l vehicles built before 8/22/2005. *tt | 11/30/2005 | |
| 05148 | 01/01/2005 | 10016809 | Low power-cold side charge air cooler (cac) disconnected-oil leak at cac connections-6.0l-vehicles built 4/1/2004 through 2/15/2005. *sc | 10/11/2005 | |
| 18283 | 11/01/2004 | 10013425 | Oil leak from the oil filter cover. *eh | 04/18/2005 | |
| 18276 | 11/01/2004 | 10013419 | Air induction system appears to be warped and or not sealing. this includes super duty f series models. *eh | 04/18/2005 | |
| 04233 | 01/01/2005 | 052625 | 10013408 | Misfire lack of power buck jerk excessive smoke crank no start 6.0l engine diagnostics for fuel system . *eh service tips. *tt | 04/18/2005 |
| 041713 | 09/06/2004 | 10013119 | Hard start or no start. *eh | 04/08/2005 | |
| 18427 | 02/01/2005 | 10012974 | Vehicle with a 6.0l engine may exhibit any one or more of the following buck jerk lacks power black smoke rolling idle surge mil on and diagnotics trouble codes p02263 or p0299. also includes 2004-05 e-series 6.0l models. *eh | 04/05/2005 | |
| 04209 | 10/18/2004 | 10010724 | Low power - cold side charge air cooler (cac) disconnected - oil leak at cold side cac connections - 6.0l engine - vehicles built 12/15/2003 through 4/1/2004. *tt | 12/07/2004 | |
| 17719 | 04/01/2004 | 10008224 | Low power/boost due to the plastic charge air cooler (cac) duct blowing off. *tt | 07/23/2004 | |
| 17288 | 10/01/2003 | 10004931 | Lack of power and/or low boost pressure condition. this includes 2003-2004 super duty f-series. *tt | 01/20/2004 | |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||||
| 052623 | 01/01/2006 | 0638 | 10019385 | Coolant degas bottle overflow - 6.0l. *tt | 03/13/2006 |
| 05249 | 01/01/2005 | 052623 | 10018939 | Coolant degas bottle overflow. *tt | 01/25/2006 |
| ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN | |||||
| 0714 | 10021236 | Lack of cooling fan operation. *kb | 03/23/2007 | ||
| ENGINE AND ENGINE COOLING - ENGINE | |||||
| TSB-09-15-6 | 12/09/2009 | 10030848 | Ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or turbocharger flutter after performing field service action (fsa) 06e17, | 12/09/2009 | |
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| 07212 | 10/01/2007 | 10023943 | Some 1997-2008 vehicles equipped with a 4.6l 2v, 5.4l 2v, or 6.8l 2v engine--spark plug thread repair procedure--not covered under new vehicle limited warranty. *nj this includes f-53 motorhome chassis. updated 2/23/10. *pe | 02/20/2008 | |
| 062401 | 10022293 | 6.0l diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct. *kb | 07/25/2007 | ||
| 06246 | 10022295 | Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17. *kb | 07/25/2007 | ||
| 19614 | 02/01/2007 | 10021619 | Air filter water ingestion / snow packing with codes p0103. *kb | 06/12/2007 | |
| 07515 | 10021464 | 6.0l oil seep or boost pressure leak at hot side charge air cooler duct. *kb | 04/27/2007 | ||
| 0754 | 10021462 | Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start. *kb | 04/27/2007 | ||
| 19375 | 09/01/2006 | 10021229 | Watch for oil flow from the base engine oil pump. vehicles equipped with a 6.0l diesel engine. *kb | 03/23/2007 | |
| 19356 | 09/01/2006 | 10021174 | Driveability issues and/or dtc p132b, p006a immediately after reprogramming. *kb | 03/19/2007 | |
| 19247 | 06/01/2006 | 10021173 | Oil flow from the base engine oil pump. *kb | 03/19/2007 | |
| 06232 | 07161 | 10020673 | 6.0l turbocharger carbon deposit diagnostics and service tips, lack of power, white or black smoke, surge, p0238, p0299, p0404, p0478, p0478, p2262, and/or p2263. *kb updated 11/05/07. *nj | 12/20/2006 | |
| 052625 | 01/01/2006 | 0697 | 10020069 | Misfire, lack of power, buck/jerk, excessive smoke or crank/no start. *tt | 07/18/2006 |
| 18362 | 01/01/2005 | 10013307 | Lack of power or runs rough condition, and/or the malfunction indicator light on with egr related diagnostic trouble codes (p0401, p0402, p0403, p0404, p0405, or p0406). *tt | 04/14/2005 | |
| 18397 | 02/01/2005 | 10012958 | Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299. *tt | 04/05/2005 | |
| 031404 | 08/23/2004 | 04161 | 10011162 | Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. to include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04. | 01/06/2005 |
| 04138 | 07/12/2004 | 10009322 | Low rpm, buck/jerk, miss, stumble after deceleration down long grade with the cruise control engaged. *tt | 09/23/2004 | |
| 0492 | 05/17/2004 | 10008548 | Water-in-fuel lamp illuminated after draining heated fuel conditioning module (hfcm) on vehicles built prior to 11/1/2003 with 6.0l engine. *tt | 08/04/2004 | |
| 17406 | 09/01/2004 | 18147 | 10008288 | Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. *mj this oasis updates previous oasis dated 12/01/03. *tt | 07/26/2004 |
| 04115 | 06/14/2004 | 04186 | 10008255 | No start or constant engine misfire - fuel injection control module (ficm) diagnosis - 6.0l diesel. *tt | 07/23/2004 |
| 17869 | 06/01/2004 | 10008263 | Air induction system appears to be warped and/or not sealing. *tt | 07/23/2004 | |
| 17683 | 04/01/2004 | 10008208 | Engine oil leaks at lower crankcase. *tt | 07/23/2004 | |
| 17667 | 03/01/2004 | 10007424 | Oil leak from front or rear of engine. *tt | 06/22/2004 | |
| 17530 | 01/01/2004 | 10007355 | Moan/drone noise and tactile vibration between 1500-2000 rpm. *tt | 06/14/2004 | |
| 17460 | 01/01/2004 | 10007317 | Oil leak that seems to be coming from head gasket area. including ford f450/550 my2003. *tt | 06/10/2004 | |
| 17266 | 10/01/2003 | 10004917 | Low base engine oil pressure caused by high pressure oil system leak. *tt | 01/20/2004 | |
| 032012 | 10/13/2003 | 10004895 | Rough/rolling idle when the engine is warm and/or white smoke after hot restart; lacks power after initial start-up; cold idle kicker performance at warm ambient temps; u0306 codes after reprogramming; p2263 code set during extended idle; f | 01/14/2004 | |
| 17252 | 10/01/2003 | 10004906 | Oil leak at, or near, the rear main seal. this includes 2003-2004 super duty f-series. *tt | 01/14/2004 | |
| 17091 | 08/01/2003 | 10003183 | No crank after powertrain control module (pcm) programming. *tt | 10/09/2003 | |
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||||
| TSB-08-26-3 | 06/01/2009 | 10028826 | Ford: some vehicles with diesel engines may experience no starts, hard starts or rough running when cold and may be accompanied with diagnostic trouble codes (dtcs) p0611, p1378 and/or all 8 injector circuit codes. *pe | 06/01/2009 | |
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| TSB-08-23-8 | 03/04/2009 | 10028125 | Ford: vehicles may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. *pe updated 3/20/09. | 03/04/2009 | |
| CSP-48B01 | 05/26/2008 | CSP-08B02-48B01 | 10026321 | Ford: vehicles mistakenly charged $100 powertrain warranty deductible for fuel injector repair or repairs. no model or model years provided. *pe econoline, excursion and f-series super duty vehicles, model years 2002-2005. updated | 10/17/2008 |
| 05135 | 01/01/2005 | 10016846 | Oil leak or boost pressure leak at hot side charge air cooler (cac) duct-6.0l diesel engine. *sc | 10/12/2005 | |
| 05139 | 01/01/2005 | 10016842 | Diesel exhaust smell in cab-6.0l engine. *sc | 10/12/2005 | |
| 17472 | 01/01/2004 | 10007321 | Low power condition and/or diagnostic trouble code (dtc) p2263. 6.0l diesel engine. also includes my2003 ford f450/550. *tt | 06/10/2004 | |
| 03146 | 05/17/2004 | 0493 | 10003746 | Engine oil diluted with fuel, runs rough and/or a low power condition. *tt | 10/29/2003 |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | |||||
| TSB-08-20-1 | 03/20/2009 | 10028284 | Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. there are several potential causes for these symptoms. *pe | 03/20/2009 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS | |||||
| 17716 | 04/01/2004 | 10008221 | Belt noise. *tt | 07/23/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - TURBO-CHARGER | |||||
| TSB-08-16-13 | 05/01/2009 | 10028730 | Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge. *pe | 05/20/2009 | |
| 19245 | 06/01/2006 | 10020150 | Repeat turbocharger or vgt replacement. *tt | 07/28/2006 | |
| 18694 | 06/01/2005 | 10017873 | Lack of power and/or dtc p2263 or p0299 after turbocharger replacement - service tip. *tt | 12/06/2005 | |
| 18069 | 08/01/2004 | 10011181 | Low power and/or diagnostic trouble code p0299 or p2263 - turbocharger diagnostic service tip. *tt | 01/07/2005 | |
| 17885 | 06/01/2004 | 10008269 | Lack of power and/or diagnostic trouble code (dtc) p2263 after turbocharger replacement. *tt | 07/23/2004 | |
| 17566 | 02/01/2004 | 10008129 | Turbo moan/drone noise and tactile vibration between 1500-2000 rpm. *tt | 07/22/2004 | |
| ENGINE AND ENGINE COOLING - ENGINE - OTHER FUEL TYPES - TURBO-CHARGER | |||||
| TSB-08-16-13 | 05/01/2009 | 10028730 | Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge. *pe | 05/20/2009 | |
| 08-2-11 | 03/01/2008 | 08-4-7 | 10024325 | 6.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08. *nj | 04/04/2008 |
| 06171 | 06183 | 10021232 | 6.0l turbocharger carbon deposit diagnostics and service tips - lack of power, white or black smoke, surge, p0238, p0299, p0404, p2262, and/or p2263. *kb | 03/23/2007 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||||
| TSB-09-15-6 | 12/09/2009 | 10030848 | Ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or turbocharger flutter after performing field service action (fsa) 06e17, | 12/09/2009 | |
| 0617 | 04/01/2006 | 10019945 | Voluntary emission recall 06e17 supplement #1: control module recalibration. corrosion may exist at the electrode surface on the exhaust pressure (ep) sensor; fuel delivery timing during cold weather may not be optimal; and/or exhaust gas | 05/17/2006 | |
| 05E15 | 08/18/2005 | 10017996 | Voluntary emission recall 05e15 - supplement #2. exhaust pressure sensor replacement, on-board diagnostic system and engine control module recalibrations. *tt | 12/12/2005 | |
| 04184 | 01/01/2004 | 10013109 | Turbo-induced exhaust moan/drone at 1600-1800 rpm - 6.0l built after 9/29/2003. *tt | 04/07/2005 | |
| 17774 | 05/01/2004 | 10008551 | Exhaust leak noise. *tt | 08/04/2004 | |
| 0494 | 05/17/2004 | 10008549 | Turbo-induced exhaust moan/drone at 1600-1800 rpm on 6.0l built prior to 9/29/2003. *tt | 08/04/2004 | |
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL - GAS RECIRCULATION VALVE (EGR VALVE) | |||||
| 07219 | 10/01/2007 | 10023855 | 6.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles. *nj | 02/06/2008 | |
| 18607 | 05/01/2005 | 10017912 | Dtc's p0488 (egr throttle position range/performance) and/or p1334 (egr throttle position sensor minimum stop performance) setting after pcm reprogramming. *tt | 12/07/2005 | |
| 05417 | 03/07/2005 | 10014666 | Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow. *tt | 05/05/2005 | |
| 17568 | 02/01/2004 | 10008131 | Normal egr (exhaust gas recirculation) operation - service tip. *tt | 07/22/2004 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| ENGINE AND ENGINE COOLING | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | ||||||
| EA05003 | FORD MOTOR COMPANY | 02/15/2005 | 11/02/2005 | ENGINE STALLING | 05V270000 | |
| In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (nhtsa recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v-270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid vin (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford | ||||||
| PE04070 | FORD MOTOR COMPANY | 10/07/2004 | 02/15/2005 | ENGINE STALLING | ||
| Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a vin (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehicles received multiple reports.odi has not yet confirmed ford's categorization of these reports, nor has odi confirmed ford's categorization of the remaining reports (which ford states do not pertain to the alleged defect).ford submitted nearly 19,000 warranty claims, many of which involved claims for a technical service bulletin (tsb 04-13-08) and field service action (fsa 03b05) which ford identified as potential remedies for stalling complaints.odi has not confirmed that either of these are a remedy for engine stalling complaints.several other dealer communications related to engine stall were also submitted as well as over 50 product modifications, 15 of which involve revisions to the software for the electronic engine control unit.further investigation is required and odi is upgrading pe04-070 to an engineering analysis (ea).during the ea, odi will establish and update manufacturer failure report counts, further investigate the frequency and trend of stalling complaints, and determine the scope and safety implication of stalling events.odi will also investigate ford's remedies, their effectiveness, and whether further action is required. | ||||||
| ENGINE AND ENGINE COOLING - ENGINE - GASOLINE | ||||||
| DP05005 | FORD MOTOR COMPANY | 09/22/2005 | 01/04/2006 | SPARK PLUG EJECTION FROM CYLINDER HEAD | ||
| On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| ENGINE AND ENGINE COOLING | |||
| 09/21/2011 | 81000 | ||
| Tl* the contact owns a 2004 ford excursion. the contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. the failure recurred on an intermittent basis. the contact also stated that the engine fan would intermittently create a very loud noise. the vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. the contact was informed that the engine would need to be rebuilt. the vehicle was not repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 81,000. | |||
| 09/21/2011 | 81000 | ||
| Tl-the contact owns a 2004 ford excursion. the contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. the failure recurred on an intermittent basis. the contact also stated that the engine fan would intermittently create a very loud noise. the vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. the contact was informed that the engine would need to be rebuilt. the vehicle was not repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 81,000. sm. | |||
| 09/21/2011 | 81000 | ||
| The contact owns a 2004 ford excursion. the contact stated that upon starting the vehicle, a large cloud of smoke emitted from the tail pipe. the failure recurred on an intermittent basis. the contact also stated that the engine fan would intermittently create a very loud noise. the vehicle was taken to an authorized dealer and the contact was informed that coolant was leaking into the engine. the contact was informed that the engine would need to be rebuilt. the vehicle was not repaired. the manufacturer was made aware of the failure, but offered no assistance. the failure mileage was 81,000. sm. | |||
| 01/06/2010 | 120000 | ||
| Tl*the contact owns a 2000 ford excursion. the contact stated the engine was turned off, and failed to restart. a certified technician replaced the fuse relay. seven months later, the identical failure recurred and the fuse relay was replaced a second time. most recent, the fuse relay was replaced each time the engine was turned off in order for the vehicle to restart normally. the vehicle was taken to an independent mechanic who was unable to duplicate the failure. the manufacturer was made aware of the failure. the approximate failure mileage was 120,000. | |||
| 01/06/2010 | 120000 | ||
| Tl-the contact owns a 2000 ford excursion. the contact stated the engine was turned off, and failed to restart. a certified technician replaced the fuse relay. seven months later, the identical failure recurred and the fuse relay was replaced a second time. most recent, the fuse relay was replaced each time the engine was turned off in order for the vehicle to restart normally. the vehicle was taken to an independent mechanic who was unable to duplicate the failure. the manufacturer was made aware of the problem. the approximate failure mileage was 120,000. js | |||
| 07/15/2010 | 95000 | ||
| Tl-the contact owns a 2004 ford excursion. while having the vehicle serviced for routine maintenance at an independent repair shop he was informed water was leaking around the egr cooler and anti freeze was leaking into the exhaust system. the vehicle was not repaired and the failure continues. the failure and current mileages were 95,000. sm. | |||
| 10/26/2009 | 74231 | 1 | |
| My 2004 ford excursion threw a spark plug from the cylinder head last week. this caused me to leave my car on the side of the road and try and find a ride home. once i got the truck home i found the coil had broken off of it's mount and the plug was resting in the hole of the head. the threads are mangled on the plug and stripped out in the head. i have researched this online and found hundreds of complaints about this same issue. please make ford take responsibility... thank you. *tr | |||
| 01/12/2009 | 85000 | 1 | |
| My 2004 ford excursion just ejected a spark plug and it's threaded bushing. this is a factory defect and should be addressed by ford and/or your office. *tr | |||
| 10/01/2006 | 48000 | 10 | 08/01/2004 |
| Dt*: the contact stated while driving various speeds, the engine stalled without warning. the vehicle was maneuvered off the road and restarted. the vehicle was driven to the dealer on several occasions for the problem where a turbo and a sensor were replaced. although the problem persisted, the dealer was unable to duplicate the problem. updated 1/10/2007 - *nm | |||
| 09/29/2004 | 13000 | 9 | 06/04/2004 |
| While driving, the vehicle surged. the consumer would smelled gas fumes inside the vehicle. the dealership was aware of the problem, but did not resolve it. *ak the turbo would not turn on and would not go over 3500 rpm's and there was a flutter type of sound coming from the driver's side rear quarter panel when the a/c was on only by the rear a/c controller. *sc | |||
| ENGINE AND ENGINE COOLING - COOLING SYSTEM | |||
| 07/14/2004 | 1 | ||
| We purchased 2004 ford excursion with the 6.0l diesel engine new in february 2004. it has been to the dealer now 2 times for the back up sensor, approximately 5 times for the turbo, unable to count the number of times for the lack of power, the vent windows not working, 3 times for the motor on the power drivers seat, ball joints 1 time, and now other front end parts. this vehicle is primarily used to go to church and travel with the entire family on the weekends for day trips. we have had it to graham ford several times, germain ford several times, (both are in columbus, ohio) and the last place we have it is donley ford in mount vernon, ohio. we can get a full history of all repairs on this vehicle if needed. there have been so many things gone wrong with the truck that it is difficult to keep track. the service advisor is now telling my wife to just trade it in. we just want all of the problems fixed correctly and find the cause of the electrical failures/issues/problems instead of just fixing what breaks and not fixing the cause. we paid 50,000 bucks for this vehicle and have had nothing but problems. the start was when we wanted to go to maine and could not take it but had to take our older conversion van. *tr | |||
| ENGINE AND ENGINE COOLING - ENGINE | |||
| 07/14/2004 | 1 | ||
| We purchased 2004 ford excursion with the 6.0l diesel engine new in february 2004. it has been to the dealer now 2 times for the back up sensor, approximately 5 times for the turbo, unable to count the number of times for the lack of power, the vent windows not working, 3 times for the motor on the power drivers seat, ball joints 1 time, and now other front end parts. this vehicle is primarily used to go to church and travel with the entire family on the weekends for day trips. we have had it to graham ford several times, germain ford several times, (both are in columbus, ohio) and the last place we have it is donley ford in mount vernon, ohio. we can get a full history of all repairs on this vehicle if needed. there have been so many things gone wrong with the truck that it is difficult to keep track. the service advisor is now telling my wife to just trade it in. we just want all of the problems fixed correctly and find the cause of the electrical failures/issues/problems instead of just fixing what breaks and not fixing the cause. we paid 50,000 bucks for this vehicle and have had nothing but problems. the start was when we wanted to go to maine and could not take it but had to take our older conversion van. *tr | |||
| 09/18/2008 | 110000 | 1 | |
| 2004 ford excursion v-10. come to a stop and the tach shows normal 650-700 rpm, and within a few seconds car will accelerate to 1800-2000 rpm by itself and the car surges forward. driver must leave plenty of space between the car and the one ahead to give him time to stop. no crash yet!!!. it does this every time you stop. *tr | |||
| 08/26/2008 | 1 | ||
| This vehicle has been serviced countless times for stalling. each time the dealer has replaced the egr valve and other items because of failure codes. each time the egr valve has failed. the dealer is repairing the vehicle and giving it back to me. within 5 minutes after receiving the vehicle from the service department, it stalls again. the vehicle will stall at least 3 times during a 30 minute drive. it stalls on the freeway, on residential streets, starting from a dead stop, and if it is driving at a constant speed. this vehicle is not fixed and it is obvious the dealer cannot fix it! it is going in tomorrow for the 3rd time this month for the same problem. i have almost gotten in an accident from it stalling, and i have had many times where i have been in a dangerous situation from it stalling. the dealer cannot fix it, i cannot sale it to another person in this condition, and ford won't do anything to help me. i am driving a very dangerous vehicle and have no way to fix it. what can i do? please give me a suggestion. do i have any rights if the vehicle cannot be fix? *tr | |||
| 05/22/2008 | 15000 | ||
| Tl*the contact owns a 2004 ford excursion. while driving approximately 25 mph, idling, or parked, the rpm's begin to increase from 2,000 to 3,000 automatically and the vehicle will occasionally stall. when driving at low speeds, the rpm's will increase from 2,000 to 5,000. the vehicle has been diagnosed by the dealer several different times, but the failure still persists. nhtsa campaign id number 05v270000 (electrical system:wiring) was referenced. the current mileage was 48,000 and failure mileage was 15,000. | |||
| 10/15/2004 | 2248 | 3 | 04/16/2004 |
| While driving, vehicle would stall. the driver was able to restart and noticed that the vehicle would accelerated suddenly on its own without warning. the driver applied the brakes the pedal went to the floor and the vehicle continue to accelerated with speed. the driver was able to maintain control of the vehicle and drove it to the dealer for inspection. the mechanic informed the driver that the problem can not be duplicated. *nm there was an oil leak. *sc | |||
| ENGINE AND ENGINE COOLING - ENGINE - DIESEL | |||
| 02/23/2010 | 1 | ||
| 2004 ford excursion diesel with 6.0 engine. the engine is crap. the fuel injectors are bad it's a known problem. i was in an intersection while making a left turn with an on coming vehicle when i had no acceleration and black exhaust was coming out of the tail pipe. i had my 3yr old daughter on that side of the vehicle. this isn't the first problem we have had with this engine as has almost everyone else that owns it. it needs to be recalled. it scared me so bad i cried. i have called the ford consumer number they did nothing. i am paying ford $1,500.00 to fix the problem that i was told would continue to happen because it's a defect in this particular engine. in the words of one of fords mechanics he wouldn't own one, they are crap i'm scared to drive it even after it gets fixed knowing another may go soon or the same one. *tr | |||
| 11/28/2009 | 78318 | ||
| Tl*the contact owns a 2004 ford excursion. the contact stated that the turbo charger on the diesel engine broke. this was caused by a malfunction within the engine. there was a 100,000 mile warranty on the vehicle and the ford manufacturer would not honor it. the failure mileage was 78,318. | |||
| 01/27/2007 | 108480 | 1 | 10/01/2003 |
| Tl*the contact owns a 2004 ford excursion. while driving between 35-40 mph, the vehicle stalled and then shut off. the vehicle was towed to a mechanic and they replaced the number 1 and number 3 fuel injectors. the dealer stated that the vin was not included in nhtsa campaign id number 05v270000 (electrical system:wiring). the current mileage was 130,994 and failure mileage was 108,480. updated 09/10/08 *bf the alternator, control module for the heating and ac system, and cooling system were replaced. updated 09/19/08. *jb | |||
| 06/02/2004 | 47000 | 4 | 09/12/2003 |
| Tl*the contact owns a 2004 ford excursion. the contact stated that the check engine light has remained illuminated in the past. the vehicle shut down and was taken to the dealer who replaced the egr valve. while driving 30 mph, the failure recurred. since then, the egr valve has been replaced several times and the turbo was cleaned. the vehicle is currently at the dealer. the manufacturer offered to buy back the vehicle for half price so that it can be resold. the current mileage is 72,876 and failure mileage was 47,000. updated 02/01/08. *lj the consumer stated the vehicle bucks forward while at a stop and while driving. *jb | |||
| 11/01/2004 | 11000 | 04/10/2004 | |
| Trucks motor cuts out losing power at diffrent times. we have been crossing intersections and pulling out into traffic and have lose the accuration. this is very dangerous. truck has been iin shop numerous of times and ford is unalbe to fix problem. | |||
| 02/05/2005 | 10 | 07/14/2004 | |
| My vehicle's engine will surge and stall. sometimes both things will happen on a given day or just one. i have had my vehicle stall coming to a stop and or driving. my vehicle's engine has surged and caused my car to move even with my foot on the brake. this has been a ongoing problem that ford can not fix. *ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM | |||
| 08/04/2011 | 55 | ||
| While driving behind this vehicle, it continually emitted dark gray to black smoke upon acceleration at each stop and each traffic light. i wrote down the vehicle license plate only to notice that the expiration date on the tages was april 2010!! this was approximately a 2010 beige ford excursion, license plate #5mkh139. | |||
| 10/12/2009 | 24000 | 1 | 01/04/2004 |
| Tl* the contact reported that the exhaust is going into the 2004 ford excursion. this has been happening for 3 months. when the vehicle is idle or stopped at a light the exhaust comes through the heating grate. the vehicle has 30000 thousand miles on it and had 24000 miles when problem started. the dealer has tried to fix the problem but nothing has worked permanently. they driver is suffering headaches and drowsiness when driving. updated 01/20/10 *bf the dealer replaced the left exhaust manifold gasket. updated 01/22/10. *jb | |||
| 10/07/2004 | 5100 | 1 | |
| While driving at any speed with the windows down consumer can smell exhaust fumes. dealership was notified, but did not resolve the problem.*ak | |||
| ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL | |||
| 08/03/2004 | 6000 | 4 | |
| The ep and egr sensors kept going out. when this happened the vehicle will run, but will not get any power, similar to stalling. this occurred three times, dealer continued to service the vehicle, and the problems came back.*ak | |||